Retention system

ABSTRACT

The present invention relates to a Disposable Bioprocess System consisting of a Single-Use-Bioreactor, a Single-Use-Pump and a single-use micro-organism retention filter. Combined most suitable for cultivation of suspended micro-organisms in a liquid media at high micro-organism concentration in a perfusion mode continuous process for expression of biological material. The inlet port of the liquid Single-Use-Pump connects via a valve to the broth reservoir of the Single-Use-Bioreactor through a liquid conveying port. The outlet port of the liquid pumping Single-Use-Pump connects via a valve to a micro-organism retention filter. And a method for operating said sterile Disposable Bioprocess System in perfusion mode for continuously processing.

TECHNICAL FIELD

The present invention relates to a Disposable Bioprocess System consisting of a Single-Use-Bioreactor, a single-use pumping device, and a single-use micro-organisms retention filter. Combined most suitable for cultivation of suspended micro-organisms in a liquid media at high micro-organism concentration for expression of biological material and methods for operating said Disposable Bioprocess System in a continuous process.

BACKGROUND OF THE INVENTION

In pharmaceutical bioreactors and fermenters the goal is to cultivate or ferment micro-organisms for production of biological materials or biomass for medical applications. Such as regenerative medicine and therapeutic applications or drugs or more traditional expression from living cells or micro-organisms of molecules for therapeutic purposes or as drugs.

The re-usable, non-disposable Stirred-Tank-Reactors (STR) being either a bioreactor or fermenter is of the size from less than one liter to more than 200 liter and formed of Stainless Steel and high quality glass. Typical volumes for lab scale STR versions are 1-20 liter comprising a glass housing / container hanging under a removable Stainless Steel head plate and the entire STR suspending in a three-leg metal structure. The head plate contains ports for sensors, sampling, gas exchange, media exchange, and a centrally oriented shaft for external mounted servo motor connection in order to insure media agitation inside the STR. Temperature are adjusted by an electrical heating blanket or water jacketing of the STR.

The disposable Stirred-Tank-Reactor were considered a novelty, and perhaps even a passing trend, as recent as mid 90ties. As the Single-Use-Bioreactors (SUB) have matured, their market acceptance for single-use equipment in general has rapidly expanded. The move to disposable production equipment is, in many instances, driven by cross contamination problems, cost reduction in steam sterilization and cleaning requirements, improved plant flexibility, reduced costs and faster time to market for the end product.

PRIOR ART

-   US 2009/0311776 and EP2141224 both from Millipore Corp describes a     pre-sterilized, disposable bioreactor made of two parts being the     rigid plastic top cover and a rigid plastic body with one or more     fluid ports in the housing body, said top cover integrates the     sensor ports and all the ports having a cap; -   US 2008/0131957 from Corning Inc - disposable symmetrical     cylindrical plastic spinner flask container with impeller on     flexible axle, three container wall integrated baffles creating     turbulence and a cover with no sensor ports; -   New Brunswick Scientific fermenter housing body model BioFlo310     consist of a metal jacketed bottom assembly, a glass cylinder and a     metal head plate. All ports except the two water heating/cooling     ports are arranged in the head plate. Further the drive motor is     arranged in the head plate; -   US 6,544,424 from Refined Technology Co. expose a liquid filtration     system comprising a cultivating storage container, a hollow fiber     filter module and a diaphragm pump performing combined as a cell     retention system for high cell density cultivation in which the     pumping device operate without valves in an alternating manner for     media recirculation; -   WO 2010055143 from Artelis S.A. describes a disposable culture     housing body with at least one external wall integrating a sensor a     culture zone and a transfer zone performing as a cell retention     system with high cell density and a centrifugal pump for media     recirculation; -   US 7,425,441 from Sartorius Stedim Biotech GmbH describes a     bioreactor with next to culturing container one or more aeration     tubes with injectors arranged; -   EP 2674480 from DASGIP Information and Process Technology GmbH     describes small disposable bioreactors (STR) designed to fit in a     parallel block (shown in FIG. 5 ). The product Bioblock perform the     temperature control and alternatively also drive of the stirring or     agitation device. The Bioblock is designed to operate 4 STRs or SUBs     in parallel encapsulating the bottom part of the STR container.

Operating the Stirred-Tank-Reactor in semi continuous process mode / perfusion mode at high cell density requires additional techniques and equipment such as a cell retention system. Combining the Stirred-Tank-Reactor with an externally arranged, stand-alone and alternate flow direction pump and a Cross-Flow-Filter device has proved well offering medium to high cell density and weeks of perfusion mode operation. Well known and dominating in the industry as ATF, the Alternating-Tangential-Flow concept by Refined Technology in New Jersey, USA allowing high cell numbers and cell free product harvest. All ATF offered are of re-usable stainless steel and glass design and not available as single-use complete setup.

Increasing need from the industry for Continuous Processing and fast multiple tests has quite surprising not promoted development of the Stirred-Tank-Reactor integrating pump and cell retention system in an all pre-sterilized single-use packages. The industry are at present stocked with traditional ATF based on glass and steel requiring subsequent frequent time consuming and costly steam sterilization. Any re-use of STR or ATF parts required to be sterile involve the subject of contamination and loss of costly culture.

Definitions relevant for the present invention:

-   The term “a” or “an” as used herein means one or more or at least     one. -   The term “alternating” as used herein describes a liquid flow of     bi-directional direction. One specific and identical volume moving     forth and backwards, no valves for flow direction control is     included. -   The term “ATF” as used by the industry and herein means     Alternating-Tangential-Flow which is a concept where the pumps     specific volume is constant and this volume is alternating, changed     back and forth (forward and reverse), the diaphragm can only move     between two end positions, no new, fresh liquid or broth is added     directly to the pump, no valves are included. -   The term “backflow” is used to describe a slight harvest return     flow, increasing the TMP, Trans Membrane-Pressure somewhat helping     high velocity flow along the membrane to remove deposits. Backflow     not to be confused with the term “backflush” being widely used in     the (rigid) membrane industry though not feasible on elastic     membranes such as “hollow fibre module”. -   The term “batch operation” as used herein refers to an operation     method with constant WV and to which no fresh media is added and no     used media and/or liquid removed, typically lasting less than one     week when cultivating micro-organisms such as CHO cells. -   The term “biological material” as used herein describes organic     compounds, tissue, cellular components, body compatible fluids,     biomass, bio-composites, biocompatible materials, antibodies in     general, DNA, RNA, proteins, molecules for therapeutic purposes and     the like. -   The term “bioreactor” as used herein means a physical device, which     biologically active environment is suitable for cultivation of     micro-organism performing a desired process suspended in liquid     media agitated by an impeller. -   The term “broth” as used herein means the non-filtered liquid     content, the cultivation soup in a fermenter or bioreactor     consisting of cells, debris, micro-organisms, media with nutrients,     waste, harvest, etc. The broth, feedstock enters the CFF and pass     the Cross-Flow-Filter membrane whereby the broth becomes slightly     concentrated retentate at the CFF exit and as such is returned into     and remixed with the broth in the bioreactor. -   The term “CHO” refers to Chinese Hamster Ovary cells being a     “micro-organism” and mammalian cell line very popular as expression     platform of proteins for the pharma industry. -   The term “container” as used herein means a hollow housing, a body     with an internal reservoir, which may be open or closed, such as     without limitation a beaker, a flask, a bottle, a tube, a vessel, a     tank, a polymeric material film bag with a wall forming the     reservoir. The container when operating as for instance a     Stirred-Tank-Reactor is typically arranged with a vertical wall and     a horizontal bottom wall pointing down wards, so that liquid or     fluid in the container is predominantly maintained inside the     container during operation mode. The container may be of cylindrical     design, or non-cylindrical design such as conical design or of     square box shaped design, a flexible film bag or combinations     hereof. The container may enclose or surround a SUB, a SUP, a CFF. -   The term “Container Volume” (CV) as used herein refer to total     volume of the housing body when used as a bioreactor or a fermenter     or a mixer. -   The term “Cross-Flow-Filter” (CFF) as used herein is a filter     device, a separating device which allow a liquid and in liquid     suspended selectable components to pass the separating device with     the liquid volume onto the other side of the device by crossing,     passing the device with certain specification eliminating desired     suspended components not to pass the separating device. The device     has a first entrance for the broth and a second exit for the     retentate. In between the broth first entrance and the retentate     second exit further a third permeate exit for the product, the     filtrate, the harvest which has passed the device. -   The term “cultivation” or “culturing” refers to hosting of     micro-organism, such as mammalian cells, in a bioreactor for     production purposes, such as expression of a product by said     micro-organisms or proliferation of said micro-organisms -   The term “deposit” or “membrane coating” or “filter cake” as used     herein refers to a process where solute, particles, micro-organisms     deposit onto a membrane surface, such as a Cross-Flow-Filter     membrane surface or even into membrane pores in a way that degrades     the membrane’s performance and increase transmembrane pressure to     undesired levels. Such deposit may be removed by increased shear     force such as high velocity of the re-circulating broth for washing     purposes. -   The term “diaphragm” as used herein is a round, somewhat dome shaped     sheet of rubber material preferably with a sealing arrangement on     the circumference. The diaphragm operate inside a housing and     separate the wetted side with broth from the SUB from the drive     fluid side. -   The term “disposable” refers to a product manufactured often from     synthetic materials preferably at low cost and to be scrapped after     use. The here presented Disposable Bioreactor System is further     bagged and pre-sterilized ready for use. -   The term “exterior facility” (area) means laboratory, production     facility, testing facility in which room(s) the Disposable     Bioprocess System is in use. In the exterior facility also the     down-stream process may take place. -   The term “fed-batch” operation as used herein refers to a bioreactor     or fermenter which start the process with a minimum media volume to     which fresh medium is added and no liquid removed until after     termination of the process. A minimum of media volume in the housing     body are inoculated with micro-organism and appear as seed train     until the maximum WV is reached prior to process termination.     Typical operation time is 2 - 3 times longer than batch operation. -   The term “fermenter” as used herein means a physical device, a     container, suitable for fermentation of micro-organism performing a     fermentation process when suspended in liquid media and agitated by     a turbine. -   The term “fermentation” as used herein refers to hosting of     micro-organisms, such as living single-celled organisms,     prokaryotes, bacteria for industrial purposes in a fermenter     expressing a product. -   The term “filter device” as used here in refer to a     Cross-Flow-Filter as mentioned as a CFF. -   The term “fluid” refers to a gas or a liquid, a gas such as air or     nitrogen at variable volume or a liquid such as water and/or oil at     constant volume or a mixture of gases and liquids. -   The term “glass” as used herein refers to transparent silica based     amorphous brittle and solid material often with excellent corrosion     resistance. -   The term “harvest” as used herein refer to the product part (such as     a protein) of the broth being the expected product generated by     micro-organism being cultivated in a bioreactor or fermented in a     fermenter. The harvest (the filtrate, the permeate) may be separated     from the broth via membrane and or CFF filtration. When permeate is     removed from the CFF the broth is then concentrated. -   The term “hollow fibre module” as used herein refer to a device made     from an outer rigid wall tube with end covers housing inside a     bundle of thin wall tubes fabricated from porous elastic material     such as polyethersulfone or other polymers. The bundle of tubes are     sealed, cast into end covers separating the tube inside from the     tube outside and hereby appearing as a Cross-Flow-Filter. -   The term “impeller” refers to a low speed fluid-agitating device     equipped with blades or vanes rotating inside a liquid filled     container for agitation, mixing, pumping, liquid circulation     purposes. -   The term “liquid suction tube” as used herein refer to a liquid     inlet, a pipe or a tube sucking, conveying the broth from the     container. The liquid suction tube convey liquid to the inlet of the     pumping device passing an inlet valve. -   The terms “media”, “growth media”, and “nutrient” as used herein are     used interchangeable and refers to a sterile complex mixture     containing mostly water, carbon sources, various gases such as     oxygen and additives such as; vitamins, hormones, growth factors,     animal serum, antibiotics, antioxidants, antifoams, cell stabilizers     and other components for cultivation of “micro-organisms”. Some     media are serum based, some are serum free, animal free, and protein     free or chemically defined media. During cultivation the combined     media and micro-organism and various debris is named “broth”. -   The term “membrane” refers to a boundary layer, which serves as a     selective barrier and remains impermeable to specific or desired     particles, molecules, or substances when exposed to the action of a     driving force (like supplied by a pump). Porous membranes are     manufactured from a variety of flexible and rigid materials such as     polymers, ceramics and metals. Appear further in the technical term     “Cross-Flow-Filter (CFF) device”. The membrane clarify a part of the     broth know as harvest. -   The term “membrane fouling” as used herein refer to the effect when     solids, cells, cell parts, cell membranes, aggregates, etc creates a     layer, a biofilm, a cake of debris on the porous membrane inlet     surface. This effect require higher TMP in order to overcome the     increased resistance on the combined membrane and deposits and keep     if desired constant flux. Membrane deposits can be removed by high     shear forces, high broth velocity and/or backflush. -   The term “micro-carrier” refer to a micro-organism supporting device     or growth bodies allowing cultivation of adherent depending     micro-organisms. Size range typical from 100 to 1.000 µm composed by     gelatine, collagen, cellulose or polymeric materials or glass and     may further be functionalized with one or more coatings. -   The terms “micro-organism” or “cells” or “biological cells” as used     herein are used interchangeable and is typically divided into: 1.     living single-celled organisms, microbes such as; fungus, algae,     moss, plankton, yeast, protozoa, eukaryotes, archaea, micro animals,     extremophiles and plant cells or the like - 2. adherent or semi     adherent or suspended living cells such as animal cells, insect     cells, mammalian cells, human cells, stem cells - 3. prokaryotes and     a variety of bacteria such as E.coli or the like - most of the above     genetically modified to solve specific tasks and product needs. -   The term “perfusion” or “cell / micro-organism retention perfusion”     mode operation as used herein refers to the operation method or     principle for a STR, SUB where the media is sequentially exchanged,     fresh nutrients sequentially added, used media / harvest removed     throughout the culture period. The micro-organisms retained in the     STR, SUB last typically 4 – 8 times longer than batch and 2 – 4     times longer fed-batch. -   The term “permeate” as used herein refers to specific parts of a     mixture, the broth, a feedstock allowed to pass through a membrane.     Also known as filtrate. -   The term “permeable membrane” as used herein refer to a porous wall,     a “membrane” allowing a liquid and selected particles (size     separation) to pass the membrane and certain particles not to pass     the porous wall, barrier, separation wall. -   The term “ports” as used herein refers to holes anywhere in a wall     allowing attachment of suitable fittings or relevant sensors or     general connections selected from the group of; PG 13,5 thread     ports, locking ports, press-in ports, or ports involving Luer-Loc     fitting, connecting fittings, sterile fittings, hoses, tubes, hose     barbs, etc. -   The term “PG 13,5” is a classical sensor (RUS) or port with a     threaded mechanical connector. PG is the technical standard term     known as Stahl-Panzer-Rohr-Gewinde. -   The term “PCS” or “Process-Control-System” as used herein refer to a     Programmable Logic Control (PLC), a Personal Computer (PC) an     Embedded Computer (EC) both integrating a Central-Processing-Unit     (CPU) electronic device with calculating power. The PLC has various     Input & Output (I/O) with input from various sensors and output for     various actuators for process control purposes. The PCS integrate     software, algorithms, process recipe in build-in memory for     managing, analysis of the cultivation or fermentation process for     on-going process alignment according to the process recipe. The PCS     correspond with a variety of sensors and actuators in order to alter     the process parameters. -   The term “PTF” as used herein refer to the new industrial     terminology and means Pulsating-Tangential-Flow being the here     presented invention. The PFT process involves a pump with a first     inlet valve and a second outlet valve in order to insure     one-directional liquid flow through the CFF. -   The term “retentate” as used herein refers to the parts,     micro-carriers, particles, “micro-organisms”, debris of a mixture     within the broth, feedstock that is held back by a “membrane”, and     do not pass the membrane as to its size, shape or charge. -   The term “scalable” as used herein refers to the feature when CV and     WV is not locked into fixed glass container dimensions. Further     refer to that the ratio between container diameter and height can be     altered accommodating end-user requirements. -   The term “sensor” as used here refers to devices able to measure     on-line quality process variables associated within a given process,     such as the level of pH, dissolved oxygen (DO), bio mass / cell     density, capacitance, conductivity, dissolved carbon dioxide,     lactate, glucose, glutamine, glutamate, ammonia, pressure, liquid     level, fluid mass-flow, velocity, temperature, viscosity, etc.     Sensor to measure SUP performance may be proximity, distance being     mechanical, optical, electrical (such as triangular laser sensor, a     pressure sensitive level sensor, or capacitance or ultra-sonic based     distance sensors). Sensors in general available as either     Re-Useable-Sensors or Single-Use-Sensors. -   The term “single-use” as used herein refers to a product designed     for use only once and to be disposed after use typically delivered     “sterilized” and ready to use, such as the “Single-Use-Bioreactor”     (SUB) and “Single-Use-Sensors” (SUS). -   The term “Single-Use-Sensors” (SUS) as used herein refer to a     disposable devices able to on-line measure analysts, process     conditions, fluid concentrations and deliver a signal, such as an     electrical signal relative to the concentration measured. The     in-expensive SUS body is designed primarily from polymeric materials     to be pre-installed in a SUB or SUF for simultaneous sterilization     all enclosed in dual or triple film bags for convenience to the     end-user who then avoid sterilization before use. -   The term “Single-Use-Bioreactor” (SUB) as used herein refer to film     bag(s) including STR or bioreactor or Single-Use-Fermenter and     preferable pre-installed with a pumping device and one or more     “Single-Use-Sensors” all manufactured from disposable materials and     sterilized and hereby ready for use eliminating the traditional     in-house heat sterilization. -   The term “Single-Use-Pump” (SUP) as used herein refer to a fluid     conveying device manufactured at least partly from disposable     materials. Such as a peristaltic pump or a centrifugal pump or a     tube pump or a diaphragm pump or a piston pump or a direct     gas-to-liquid surface driven air column pump or the like comprising     disposable wetted part and re-usable non-wetted parts and a valve     for flow direction control. -   The term “Stainless Steel” as used herein refers to an alloyed metal     based mostly on nickel, chromium, vanadium, carbon, and steel     characterized with at least excellent corrosion resistance. -   The term “sterilization” as used herein refer to any process that     eliminates (removes) or kills (deactivates) all forms of life and     other biological agents. Sterilization can be achieved with one or     more of the following: heat, chemicals, irradiation, high pressure,     and filtration. -   The term “sterilized” as used herein refers to a product enclosed in     a plastic film bags and exposed to sterilization methods which     insure the bag content is sterile. The product is supplied in said     film bag(s) to the end-user ready to open and use. The end-user     hereby avoids the troublesome heat sterilization similar to     classical re-usable equipment processed in an autoclave. -   The term “Stirred-Tank-Reactor” (STR) is a widely used expression     and as used herein refer to a bioreactor or fermenter with a     “Container Volume” (CV) integrating an aeration device and agitation     or mixing device(s) for forced exchange of nutrient and gas with the     “micro-organisms” within said media. STR are manufactured     predominantly from stainless steel and glass. -   The term “suspension” or “suspended” as used herein refers to     particles, artificial particles, micro-carriers, micro-organism     depending on being preferably homogeneous suspended or mobilized in     liquid (in the broth) in the STR or SUB or “container”. -   The term “Tangential Flow Filter” (TFF) as used herein is a device     which allow selectable components under pressure to pass from one     liquid volume into another liquid volume crossing a “membrane”     (cross-flow-filter) eliminating some components to pass the     membrane. Such membranes or filter devices may be based on screens,     porous material sheets integrated into cassettes or shaped as flat     or round plate, tubes, corrugated tubes or stacked hollow fibres     into a cartridge. -   The term “top cover” as used herein refers to the upper, typically     head plate, such as flat metal disc for the classical STR. The top     cover is without limitation selected from the dominant Stainless     Steel / glass STR design supplied by Sartorius, Applikon, Finesse,     Broadley-James and app 20 other suppliers since the 70ties. Number     of PG 13,5 ports available effected by the top cover diameter and in     general being three to four ports. The top cover may take other     shapes than the flat disc and be equipped with one or more ports. -   The term “TMP” or “Trans-Membrane-Pressure” as used herein describes     an excellent indicator of membrane fouling. Accumulated cells,     debris, particles on the membrane surface. TMP increases to     compensate for the membrane fouling at constant flux. -   The term “Working Volume” (WV) as used herein refers to the media     volume, process fluid, the broth in which the cultivation takes     place inside the STR or SUB. Further the “head space volume” +     Working Volume = Container Volume (CV).

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the complete PTF operating SUB with a SUP and a CFF integrated

FIG. 2 shows a tube penetrating the container vertical side wall

FIG. 3 shows a tube penetrating the container vertical side wall

FIG. 4 shows a tube connected to a one-way valve and a pump

FIG. 5 shows the invention mounted in a parallel operating Bioblock

FIG. 6 shows a PTF setup with a diaphragm SUP between a SUB and a CFF

FIG. 7A illustrates a PTF pump with valves and a Cross-Flow-Filter mounted

FIG. 7B illustrates a PTF pump with valves and a Cross-Flow-Filter mounted

FIG. 8 illustrates a possible flow and process diagram

SHORT PRESENTATION OF THE INVENTION

The present invention relates to a Disposable Bioprocess System supporting biological activity comprising a fluid tight container comprising a process liquid broth volume surrounded by walls separating an interior process liquid volume from an exterior facility area wherein said process liquid volume communicates with a first liquid valve and a conveying liquid pumping device for pumping the process liquid in one direction away from the interior process liquid volume, and a second liquid valve and a filter device separating the interior process liquid volume from the exterior facility area wherein means of liquid communication from the interior process liquid volume of said fluid tight container to said liquid pumping device a further means of non-filtered liquid communication extends from said pumping device to a non-filtered first liquid communication port of said filter device, and further means for non-filtered retentate liquid re-circulated via a second liquid communication port of said filter back to the interior process liquid volume of said container, said filter device comprises at least one third permeate outlet port for conveying filtered process liquid to said exterior facility area as harvested product wherein the first liquid valve controls the communication between the interior process liquid volume and the pumping device, wherein the second liquid valve controls the communication between the pumping device and the filter device, and wherein a filter outlet port communicate between the filter device and the exterior facility area.

DETAILED PRESENTATION OF THE INVENTION

It is an object of the present invention to provide a Disposable Bioprocess System supporting biological activity comprising: a fluid tight container comprising a process liquid broth volume surrounded by walls separating an interior process liquid volume from an exterior facility area wherein said process liquid volume communicates with a first liquid valve and a conveying liquid pumping device for pumping the process liquid in one direction away from the interior process liquid volume, and a second liquid valve and a filter device separating the interior process liquid volume from the exterior facility area wherein means of liquid communication from the interior process liquid volume (12 d) of said fluid tight container (12 a) to said liquid pumping device (15) a further means of non-filtered liquid communication extends from said pumping device (15) to a non-filtered first liquid communication port of said filter device (16), and further means for non-filtered retentate liquid re-circulated via a second liquid communication port (16 a) of said filter device back to the interior process liquid volume of said container, said filter device comprises at least one third permeate outlet port (16 d, 16 e) for conveying filtered process liquid to said exterior facility area as harvested product; wherein the first liquid valve controls the communication between the interior process liquid volume and the pumping device, wherein the second liquid valve controls the communication between the pumping device and the filter device, and wherein a filter device outlet port communicate between the filter device and the exterior facility area.

The presented invention is a Disposable Bioprocess System for Continuous Processing of micro-organisms in the pharmaceutical industry integrating a Single-Use-Bioreactor (SUB), a Single-Use-Pump (SUP) and a single-use CFF based micro-organism retention device. Operating after the term Pulsating-Tangential-Flow, PTF of the Disposable Bioprocess System offer end-user benefits, freedom and features such as:

-   Eliminate traditional time consuming steam sterilization as the PTF     invention is pre-assembled, pre-sterilized with all necessary     components ready for use right out of the box for lower cost of use     and higher throughput in laboratories; -   Eliminate cross contamination as to the pre-assembled and     pre-sterilized concept beneficial to both Research & Development as     well full scale production; -   Minimizes instalment time as the PTF cell retention system integrate     the SUP and CFF either inside the SUB or outside of the SUB     container, which also allow instalment in parallel block’s or     robotic devices for desired perfusion mode processes; -   Un-parallel control of broth velocities and volume through the CFF     for different harvest and cleaning cycles by a sensor measuring     on-line liquid level (potentially separated by a diaphragm or     piston) inside the SUP; -   The Disposable Bioprocess System enables rapid evaluation of     multiple micro-organism cultures, increasing productivity in cell     line development with significant savings on materials and labour.

The pharmaceutical industry desires a SUB platform supporting increased volumetric efficiency, more on-line analyst measures all in a single-use design with capability intended for micro-organism retention in perfusion mode operation. Potentially in parallel processing with semi-automated robots such as the DASGIP parallel operating Bioblock or the fully automated TAP Biosystem (from now Sartorius Stedim Biotech) or individually performing the continuous processing. For reasons unknown such Disposable Bioprocess System product as presented here does not exist today.

The present invention relates to a Disposable Bioprocess System comprising a SUB for cultivation or a SUF for fermenting of biomass and selected components comprising advantages (below briefly described) such as;

-   A container comprising a range of ports, mechanical connected with     or an integrated part of a hollow plastic container with an interior     reservoir optionally with one or more side wall ports. The container     have selectable diameter or cross section (such as round,     cylindrical or non-cylindrical such as square design) and heights     offering a desired interior reservoir and respective volume; -   Optionally a draft tube stator arranged vertical inside said     container operating with none or one or more baffles arranged     perpendicular and radially to said draft tube stator exterior space     said draft tube stator having an interior space housing fluid     motion, agitation means. The interior reservoir fluid agitation     device(s) create a radial swirl of media which the tube stator     convert into axial fluid movement and more efficient mixing axial     vortexes; -   Optionally a baffle arranged vertical inside said container     operating as a SUB extending inwards from the container side wall; -   A fluid motion, agitating device arranged on a rotating shaft     attached to component comprising magnets and a bearing in contact     with the container bottom for magnetic power transfer through the     bottom wall driven by external magnetic means; -   A fluid motion, agitation device arranged on a rotating shaft     penetrating the container top via a bearing / sealing arrangements     for kinetic power input; -   A tube arranged vertical inside said container with the purpose of     supplying a mixed gas addition to insure for the cells safe     aeration; -   Liquid communication between the broth of the container and a     Single-Use-Pump device, said SUP devise a liquid conveying or/and     liquid direction control device in order to facilitate the pumping     operation. Said SUP device may be arranged inside the container or     external to the container; -   Liquid communication between the container a single-use     Cross-Flow-Filter devices, said CFF devise and one or more liquid     conveying or/and pumping devices and liquid direction control     devices in order to facilitate the advantageous micro-organism     retention under perfusion mode operation. Said CFF device(s) may be     arranged inside the container and/or external to the container; -   Manufactured from materials considered to be disposable and supplied     sterilized to the end-user for cost efficient single-use     applications.

Dimension of the SUB container are not limited by, but may correspond the preferred dimension of the Bioblock or robot assembly to which the STR may be installed in. The container provides an interior space with exterior walls and two in principle flat end covers being top cover and bottom cover. Dimension of the container, housing assembly range 10 to 500 mm in diameter such as 20 to 200 mm and height from 10 to 1.000 mm such as 50 to 500 mm. Or measured in container cross section from 1 to 2.000 cm2. Or measured in CV ranging few millilitre up to 2.000 liter.

The invented Disposable Bioprocess System further comprise a variety of additional arranged devices and features in order to expand the simple batch operation to the more advantageous perfusion mode operation. Such as one or more; hollow bodies appearing as reservoirs, Cross-Flow-Filter devices, aeration devices, instrumentation, sensors, liquid conveying devices, valves, actuators, fluid accumulators and the like for regulating process means.

In addition the invented Disposable Bioprocess System comprises a Single-Use-Bioreactor a liquid conveying or pumping device and a Cross-Flow-Filter device for micro-organism retention perfusion mode operation. Such CFF may be manufactured from rigid porous ceramic support integrating a thin micro-porous membrane into a honeycomb module or manufactured from flexible semi-permeable flat or round membranes or hollow fibers bundled into a cartridge. The CFF are arranged in liquid contact with the process liquid broth either inside of the SUB or outside of or next to the SUB either above or next to the SUB with drainage from the SUB either above or below the container broth level. The CFF are sequentially exposed to liquid feed drawn by a liquid conveying device from the SUB process liquid reservoir through valve means into and occupying the entire interior, retentate compartment of the CFF retentate channels. After partly or fully closing of both liquid conveying inlet and CFF outlet valves the liquid conveying creates TMP across the CFF membrane. Which allows at least a part of the expressed and desired protein product from the processes suspended in the media to pass over the membrane and hereby be converted to permeate, harvest. The remaining micro-organism rich liquids and suspended debris inside the CFF are simultaneously converted to retentate and returned by flushing through CFF exit to the reservoir by suitable velocity for the liquid conveying operation. The permeate side of the CFF may preferably be exposed to a pressure below the retentate liquid pressure in order to overcome the TMP losses. In fact - its preferred that a force on the permeate side helps overcome the TMP of the semi-permeable membrane as limited liquids pass the membrane mostly caused by a membrane fouling, deposits typically created from the broth on the retentate side of the CFF.

The present invented Disposable Bioprocess System supports numerous requirements and facilitate a variety of rigid or semi-rigid or flexible products used for fabrication of basic parts. Materials such as polymers to form one or more parts of the invention are, but not limited to materials such as; polycarbonates, polyesters, nylons, polyamide, PTFE resins and other fluoropolymers, acrylic and methacrylic resins and copolyrners, polysulphones, polyethersulphones, polyarylsulphones, polystyrenes, polyetherimides, polyethylene terephthalates, polyvinyl chloridcs, chlorinatcd polyvinyl chloridcs, ABS and its alloys and blends, polyolefins, preferably polyethylenes such as linear low density polyethylene, low density polyethylene, high density polyethylene, and ultrahigh molecular weight polyethylene and copolymers thereof, polypropylene and copolymers thereof and metallocene generated polyolefins. Or partly, semi rigid materials such as silicone, rubber and otherwise elastic materials.

The basic individual parts of the container manufactured by or assembled from:

-   injection moulding or blow moulding or vacuum-thermo shaping of     basic parts; -   welding basic parts together; -   moulding basic part pieces together via injection moulding process; -   sealing of basic parts between assembling surfaces by elastomeric     element(s) such as an O-ring or flat washers or diaphragms may be     nitrile rubber, silicone rubber, Viton rubber, latex rubber, EPDM or     other elastic material; -   sealing basic parts between assembling surfaces by adhesive     materials such as UV curing adhesives or epoxy’s and the like,

or combinations hereof.

In a first embodiment the invented Disposable Bioprocess System provides a container according to the invention manufactured from disposable materials suitable for micro-organism retention perfusion mode comprising in a liquid loop:

-   various ports arranged on said first container exterior wall for     implementing sensors measuring process parameters; -   further various tubes, hoses, ports pass though the outer wall of     which some extending to and or from the first container interior     volume for various fluid communication with external devices, such     as a liquid suction tube for connecting to the second container     operating as a SUP; -   furthermore attending the first container a second tubular container     operating as a SUP with a suitable interior volume comprising a     first inlet port and a second outlet port and said container closed     with a bottom cover, a top cover and comprising a liquid level     sensor; -   furthermore attending the first container and second container     arranged in liquid series a CFF device comprising a housing a micro     porous internal separation wall a first inlet a second exit and a     third harvest port; -   furthermore attending the first and second container and CFF device     arranged a first valve guiding broth in one direction from first     container to second container and a second valve conveying broth in     one direction from second container to CFF device and a liquid     connection from CFF device in return to said first container closing     the liquid loop.

In a second embodiment the invented Disposable Bioprocess System provides a first container suitable for micro-organism perfusion mode operation comprising:

-   various PG 13,5 ports arranged on the first container exterior wall     for implementing sensors measuring various process parameters; -   further various tubes, hoses pass though said first container     exterior wall of which some extending to and or from the interior     volume of said first container for various fluid communication with     exterior devices; -   a port arranged on the first container exterior wall furthermore for     implementing a broth suction tube for conveying broth to a second     container operating as a SUP. Said broth inlet from said first     container comprising a suction tube inside first container is     independent of penetrating said first container upper exterior wall     the invented and presented Disposable Bioprocess System also becomes     independent of the first container physical dimension - a valuable     feature of the invention; -   furthermore attending the first container a second tubular container     operating as a SUP with a suitable interior volume comprising a     first inlet port and a second outlet port and said container closed     with a bottom cover, a top cover and comprising a liquid level     sensor; -   furthermore attending the first container and second container     arranged in liquid series a CFF device comprising a housing a micro     porous internal separation wall a first inlet a second exit and a     third harvest port; -   CFF second exit port return processed liquid via a tube to first     container completing the PTF concept; -   CFF third outlet is considered harvest port; -   SUP and CFF containers arranged independent of each other; -   a liquid agitating impeller or turbine arranged on a shaft inside     the reservoir of the first container said shaft driven in rotation     by external means;

The first liquid conveying variation of the invented Disposable Bioprocess System takes advantage of a second container operating as the liquid broth conveying pump and arranged in series in liquid connection to said first container. The interior space of said second container represent a first liquid broth and a second drive gas compartment. The process broth arrives from the container and contain micro-organism and various debris. The second container being the SUP comprises:

-   a first inlet valve convey liquid from the first container liquid,     broth reservoir; -   a second outlet valve which convey liquid broth to the CFF device     first inlet port; -   a drive gas connection corresponding with external drive gas control     means adjusting continuously the broth level height, the broth     volume and velocity of the broth being conveyed by the pumping     device in reciprocating action in a sequential though continues, one     way, single direction liquid movement (opposite of alternating     liquid movement which is dual-way liquid movement); -   a SUP activity sensor - such as a liquid surface height measuring     sensor, or a liquid volume measuring sensor, such a internal or     external arranged Single-Use-Sensors or Re-Usable-Sensors.

Said CFF device second exit side corresponds with an optional third valve said third valve outlet which correspond with the first container process broth reservoir finalizing the closed liquid loop. The SUP container as well as the valves and the CFF device may be arranged outside or inside the SUB container. And more than one of each of the SUP and of the CFF may be integrated with or within the SUB. In any suitable combination and numbers promoting the process.

If desirable there may be a separating device between the drive gas compartment and the liquid broth compartment inside the second container. Such as a diaphragm, a piston, a discs, wet on one side and dry, semi-dry on the opposite side.

For the cultivation start a desired amount of media covering at least sensors and agitation devices in the SUB is inoculated according to the desired recipe. When desired biomass and WV has reached its potential the process is converted from batch to retention perfusion mode operation.

Perfusion process of this invention is the combination of several different operations modes, principles: 1. Cultivation mode (typically continues for weeks in the SUB), 2. Harvest - the “membrane conveying mode” at low velocity in CFF. 3. Deposit removal - the “membrane cleaning mode” at high velocity in CFF.

Different and independent operational modes following each other at desired intervals as described here:

-   process liquid of said SUB corresponds with one first valve insuring     a one way, single direction fluid path from SUB to SUP; -   said first valve corresponds with one associated liquid conveying     SUP; -   said liquid conveying SUP of variable capacity of / and pressure     applied to the process broth conveyed from said SUB through said     first valve; -   said liquid conveying SUP convey process broth in one direction (not     alternating) through a second valve and to the first inlet of said     CFF device(s) and further through the CFF inlet channels, across the     membrane; -   to the retentate side of said CFF device(s) with volume and velocity     though reduced pressure passing along the CFF device retentate     membrane side to said CFF device opposite second outlet / end; -   and said processed fluid returned to said SUB - when in membrane     cleaning mode sequentially high velocity flushing removes the     membrane fouling, deposits, which is returned to the SUB; -   involving an optional third valve after the retentate / CFF exit     when at least partly closed allow the liquid conveying SUP to apply     higher pressure to the retentate side of said membrane(s) of said     CFF device convey harvest through its pores by separating, avoiding     micro-organisms and other particles from passing though said     membrane said liquid when passed the membrane is considered to be     the harvest or harvested product - when in membrane conveying mode; -   said harvested product is separated from the permeate side of said     CFF device and collected externally and forwarded to down-stream     processing; -   a volume from the cultivation broth (cell bleed) in said scalable     Single-Use-Bioreactor is removed sequentially as waste in order to     reduce the exponential growth and keep total desired bio mass at     desired level; -   a corresponding volume fresh media is added, replenished to the     first container, SUB accordingly; -   completing a cycle.

It is desirable to extent from the short SUB batch cultivation time (one week) and low micro-organism numbers high / bio mass (5-10 × 10E6 cells / millilitre. Practical PTF operational cell density range 20 - 100 × 10E6 cells / millilitre preferably measured with an on-line bio mass sensor. High cell density in general means higher productivity for the SUB. Longer cultivation time means more throughput, less time spend in starting the cultivation per run. A conventional batch process last one week plus one week for cleaning and process restart. It takes 7-10 days of batch cultivation before the PTF process can start. Continuous processing time of 5-6 weeks is relevant with 5-10 times the cell density to batch. With the present invention only one day is requited to start the next process. Compared batch against PTF then PTF is 30 times the amount of cells producing and product harvested.

The benefits of the second container representing the air column driven liquid conveying SUP (FIG. 1 ) are: low shear stress for the suspended cells, able to handle micro-carriers, neither micro-carries or cells damaged now not passing a peristaltic pump, no problems with clocking of the CFF as the setup is not a dead-end filtration, no alternating liquid flow, simplified operation, good control of liquid velocity and most important simplicity and of low cost allowing the SUP device to be designed from plastics and integrated fully and sterilized in the Disposable Bioprocess System.

General conditions for the first container, the SUB is that single micro-organisms may be kept in suspension or multiple micro-organisms aggregated in colonies kept in suspension or multiple micro-organisms adhered to micro-carriers kept in suspension.

A third embodiment comprises one or more containers if desired with different diameter and height and interior space volume. Either external to each other or the first container is arranged outside the second container which is here surrounding by the first container. The first container interior space contains process liquid broth including micro-organism and the second container being the SUP convey the broth and a third or optionally fourth containers being CFF devices. The second container interior space represent the air driven SUP pumping reservoir. The second container comprises a drive gas inlet, a first process broth inlet and a second process broth outlet. Said SUP first process liquid inlet correspond with the first SUB container reservoir via the first valve and the conveyed process liquid passing the second valve correspond via the second process liquid outlet corresponding with the first inlet of the broth side of a first CFF device. Said CFF device convey the broth to the retentate second exit retuned to the SUB. Said CF device from its permeate third exit convey the micro-organism free liquid via appropriate connections with external means for harvest being withdrawn from the all sterile setup.

Supply of controlled sterile drive gas volume and pressure to the second SUP container head space allow pressure control of the head space volume above the process liquid broth. Controlling head space drive gas pressure controls the process liquid surface level height. As the process liquid level in the first container is lower than second container liquid level and process fluid must pass the first valve to be conveyed into the second container interior space volume this is all controlled by the second container head space gas pressure. Variation in head space gas pressure regulate the liquid level and combined with a optional third valve supply process liquid under TMP control for harvest. Or process fluid at high velocity for removal of deposit on the membrane surfaces on the retentate side. The CFF benefit from on its retentate outlet an optional controlled third valve with liquid outlet connected to the first container process liquid reservoir. When the third valve is opened the membrane cleaning pulse of high velocity liquid is returned, conveyed back to first container process fluid reservoir.

Bringing the perfusion process into operation require the first container hold the process liquid and the suspended micro-organisms for the cultivation as a broth. A least one CFF operate sequentially separating the micro-organism (or micro-carriers) from the process liquid and hereby keep the micro-organisms predominantly inside the first container interior space at any time. One or more SUP and one or more CFF may operate in parallel if desired and even with different specification and different control parameters.

It’s end-user experience that the traditional and only commercial available stainless steel housing encapsulated CFF limits the process time as to extended membrane deposit issues. When the one and only CFF device module loose transport capability it is impossible to exchange the CFF and re-insert a new fresh CFF under sterile conditions.

The presented invention promote extended cultivation time by facilitating more than one pre-installed CFF internal as well as external to the first container. This feature allow users to extent the first container process operation time in perfusion mode by the number of connected, installed CFF modules.

The presented invention allow one liquid conveying second SUP container to be connected with one or more CFF devices. Performance of each CFF may be monitored continuously, such as by pressure drop (TMP) and mass flow sensors. The CFF may be of different size and different specifications. When the life time of the first CFF has reached a relevant upper limit of transmembrane pressure said CFF is blocked of by the third valve and the next and fresh CFF is brought into use - without risking / jeopardizing the sterile setup. The first and second valve preferably are low cost valves to be integrated in the invention. The third, fourth and more valves may be controlled hose / pinch valve allowing the complete process loop as presented in FIG. 8 to be pre-assembled and pre-sterilized hereby creating one sterile component fully eliminating further need for local sterilization.

In a fourth preferred embodiment (see FIG. 6 ) a free floating and non-controlled diaphragm based SUP is provided which convey broth from the SUB to and through the CFF. The SUP comprises two housing parts each with an interior chamber and groves for O-ring sealing on the circumference separated by and also sealed with when assembled by an elastic element. Said elastic element is a moulded thin flexible sheet integrated with a sealing O-ring on the circumference. Material preferably with compatibility with the requirement of the biological process. Upper single-use curved dome part comprises two ports; a first inlet port for SUB connection via a first one-way valve and a second exit port for CFF connection via a one-way valve. The lower potential re-usable housing part comprises a port for drive gas connection. Such as controlled drive gas pressure between vacuum and shop compressed air. The diaphragm have two positions being maximum expanded to each of the two end positions as determined by the two pump housing parts interior dimension.

The SUB is a container with magnetic agitation transfer through the bottom plate of the container. Various agitation devices may be added to the SUB such as the shown rotating shaft mounted with an impeller and driven by an external rotational force. A suction tube penetrate through the SUB wall into the SUB interior broth volume for suction of broth. The suction tube convey via a hose to a first one-way inlet valve located outside on the SUP dome to the SUP upper interior liquid chamber between the elastic diaphragm and the upper dome housing. The elastic diaphragm separate the sterile, wetted environment on the upper side and below the non-wetted non sterile drive gas compartment. The SUB suction tube ends into a hose which continues to the first valve inlet barb. The first valve allow one direction broth flow from the SUB into the SUP chamber. The second valve allow one direction broth flow from the SUP pumping chamber to the CFF inlet port. The CFF facilities the broth to pass along its channels to the CFF exit from which a hose insure the now retentate is guided back into the SUB and mixed with the broth finishing the liquid cycle.

Further in a fifth preferred embodiment (see FIG. 7 ) the SUP for combined SUB and CFF operation in a perfusion process setup is a diaphragm pump. An SUP example is described in WO2010/069321 being a free-floating and both in motion and position controlled elastic diaphragm is provided which convey broth from the SUB to and through the CFF. The SUP comprises two housing parts each with an interior chamber and groves for O-ring sealing on the circumference separated by and also sealed with when assembled by an elastic element. Said elastic element is a moulded thin flexible diaphragm integrated with a sealing O-ring on the circumference. Material preferably with compatibility with the requirement of the biological process. Upper single-use curved dome part comprises two ports; a first inlet port for SUB connection via a first one-way valve and a second exit port for CFF connection via a one-way valve. The lower housing part comprises a port for drive gas connection. Such as controlled drive gas pressure between vacuum and shop compressed air. The re-usable lower pump housing is equipped with a sensor for determining the position of the elastic diaphragm in real-time and possible 0,1 mm accuracy. Data from a position sensor will allow velocity and volume control of the SUP by modern electronics able to calculate input against PID algorithms and output for real-time regulating a proportional valve opening for variable drive gas pressure on the non-wetted side of the diaphragm. Said diaphragm will change position accordingly and respectively move a desired portion of liquid according to selected diaphragm position. The diaphragm based pump operate in series with valves and arranged between the SUB and CFF and with one first valve on the inlet side of the SUP and one second valve on the pump outlet side facing the CFF retentate inlet side. Optionally one third valve on the CFF outlet side for TMP control. The diaphragm pump collaborate and operated in series with the first and second valves. Which allow control of and insure one-direction flow being the invented PTF concept. The SUP control liquid volume and velocity of the broth through the CFF and volume of harvest and re-circulation volume on the retentate side of the CFF. Pressure is supplied by the SUP in order to overcome the gradually increasing TMP in the harvest situation. Broth velocity in order to sequentially flush out collected membrane deposit restoring CFF transmembrane pressure to its original stage.

Overcoming increasing TMP is established when the SUP is filled with process broth and the CFF is filled with process broth and first valve closed, second valve open and third optionally valve partly closed. Expanding controlled the diaphragm of said pump will increase system pressure and overcome TMP and the membrane will convey liquid and hereby converts retentate to permeate as the desired type of harvest.

One practical way of procedure is when the SUP diaphragm is in the relaxed stage and pump chamber and the CFF is filled with process broth and only the first valve is closed. The optional third valve arranged in the opposite end of the CFF, with relevance to the pump, is now open and allow high velocity liquid (like from 1 to 20 m/s) to be pumped with one or more pulses through the CFF. Said liquid broth pass the open third valve and return back into the SUB reservoir dragging along the collected cell material, deposit, etc from the CFF retentate membrane surfaces. The liquid loop is that all components is both supplied such as and operate in a closed loop. No alternating flow of liquids is required for membrane deposit removal. Only one liquid direction in the invented PTF setup hereby improve in general system and in specific the CFF performance as “fresh” process liquid broth is used for sequential membrane cleaning.

The SUP in the embodiment of a diaphragm pump is based on a flexible and/or elastic element being the diaphragm able to expand to a desired shape and / or return to a desired shape when exposed to as drive gas pressure ranging from vacuum to atmospheric overpressure. Movement of the flexible and / or elastic element with drive gas on one side and process liquid on the other side separates the non-sterile, non-wetted side with the wetted and sterile environment. Furthermore the diaphragm may take different shapes and be arranged anywhere outside as well as inside the container or part the rigid container wall or partially outside and inside on the container wall. The diaphragm may take shaped as a sheet of elastic material, shape as a sphere, shape partially as a sphere, shape as a tube, shape as a cylinder, shape partially as a cylinder closed in one end.

For the invented PTF the first and second valve may be a passive one-way valve know in the industry as umbrella valves or ball valves or buck bill valves. Or valves controlled by external means such as pinch valves or hose valves or sheet valves or poppet valves or combinations hereof.

The person experienced in working with membrane filtration know that deposits, debris, clogging is a significant problem. Deposits on elastic membranes may during the process be removed with controlled rapid changes in broth velocity. Pumps as used in cell retention CFF systems on the market from Spectrum Laboratories Inc, CA, USA and from Refined Technology (now Repligen Corp, MA, USA) do not allow rapid changes in broth velocities. Spectrum Laboratories use centrifugal pumps and Refined Technology a limited flexibility in movement diaphragm pump.

The present invention benefit from huge span in rapid broth velocity changes (measured in meter/second) passing along the CFF membrane surface. For harvest mode low velocities like from 0,01 to 1 m/s is sufficient. For cleaning cycles higher velocities will promote removal of deposits at 1 to 20 m/s or more. The SUP of the system are able to controlled alter velocity between the individual pumping cycles from lowest to highest velocity from one to the next pumping cycle. Hereby the expression “harvest cycle” and “cleaning cycle” is created. Utilising better CFF performance and longer process life time before the otherwise accumulating CFF deposits limit process performance and the cultivation is terminated.

Exchange of thermal energy of the media reservoir such as heating for cultivation and cooling for fermentation may be performed by encapsulating the SUB with heating blankets or water jacketed systems.

Thermal control can also be used to control the total biomass, cell density in the broth. As an example mammalian cell lines such as CHO cells operate at maximum cell growth rate at 37° C. They more or less divide once per 24 hours and hereby grow exponentially and will as to such eventually block the SUB. Reducing temperature with 3 to 10° C. will allow a stable cell density, cell population in the SUB such as 20 to 100 × 10E6 cells / millilitre for weeks.

Further desktop arranged parallel blocks, sockets, workstation, robots for insertion of the invented Disposable Bioprocess System will further give benefits such as easier sampling, simplified connection of the sensors to cabling and the associated PCS. The parallel operating setup may take any shape facilitating the installed SUB bodies. SUBs may be arranged in one or more rows arranged in both directions creating assemblies with from 1 to 48 SUBs or more in one setup.

Alternating-Tangential-Flow Details

The market dominating Alternating-Tangential-Flow concept “ATF” from Refined Technology is a dual flow direction, bi-directional flow concept in pulses. ATF offer reduced liquid exchange inside the Cross-Flow-Filter device as the CFF internal volume is not exchanged fully with fresh liquid at each stroke. Un-controlled dilution takes place inside the CFF.

The diaphragm pump of the ATF further offer only two positions for the elastic diaphragm. Two end positions and no positions in between allow no functionality as metering pump benefits except the total volume. The ATF diaphragm pump can only pump one specific volume being the particular pump size volume. As to this fact a range of pump sizes is required for different CFF sizes and different STRs. No valves are described in reference or used in practise for flow control or flow direction. The ATF concept pump do not allow programming for precise and selected pumped volumes for optimum perfusion performance and not combined with high velocities for controlled deposit removal prolonging the CFF lifetime.

ATF perfusion systems with cell retention CFF devices operate conventional glass/steel STR from 3 litre lab scale to 500 litre all steel production scale volume covered by 5 different pump sizes. The entire ATF selection of 5 pump sizes named ATF-2, 4, 5, 8, 10 cover a scalable factor of app. 1:55 over the entire range. The ATF pumps can only offer one full stroke in pumping capacity and not fractions of a stroke. Pump ATF-2 exchange 0.1 litre, ATF-4 exchange 0,4 litre - ATF 6 exchange 1,3 litre, ATF-8 exchange 2,5 litre, ATF-10 exchange 5,5 litre per stroke. Each of the 5 different pumps offer individual scalability of app 1:5 to STR volume. Each ATF pump must be connected to one specific size CFF with max ± 10 % surface area (app 0,1 or 0,75 or 2,5 or 4,2 or 10 m2) as to pump limitations. None of the ATF systems (pump housing, CFF housing, connections) is available in pre-assembled and pre-sterilised and disposable design. ATF is only available in stainless steel for manual mounting, insert of the CFF module, steam sterilization and rather complicated connection with the STR or large scale steel vessels.

Pulsating-Tangential-Flow Details

In comparison the present PTF invention utilise one liquid flow direction, monodirectional, single flow direction in pulses. The present invention utilize the entire CFF broth volume exchange each time a pulse appear from the SUP. Fresh broth, liquid is always added to the SUP controlled by a valve. The present invention allow full control of velocity from 0,01 to 20 m/sec and volume performed by the SUP, when integrating a sensor.

The invented Disposable Bioprocess System operating in PTF mode take advantage of a variety of pump principles.

In the present invention the second container SUP (FIGS. 1-5 ) is also a metering pump, when integrating a sensor, able to flow a desired and pre-controlled volume independent of time. The SUP can exchange a volume, such as the exact broth volume of the inside volume of the CFF at each pulse. With a stroke resolution of 0,1 mm and a 150 mm max stroke of the in FIG. 1 shown embodiment gives incredible 1:1.500 in volume variation in just one SUP size. Further one pump size will be able to satisfy the requirements of a very wide range of CFF modules with a factor 1:50 surface area and 1:50 range of SUBs which all reduce end-user investment. Perfusion system (PTF) of the present inventions will allow SUB sizes down to 0,25 litre SUB laboratory scale VV and up-scalable with impressive factor 500 with just one SUP size.

The present invention integrate a SUB with a SUP, a range of SUS, a single-use CFF, all hoses and all connections all fully pre-assembled, pre-sterilised and fully disposable for very simple and ease of use and much higher throughput at end-user site.

In the present invention the diaphragm pump (FIGS. 6 and 7 ) when integrating a sensor, utilise an extraordinary performance width in pumped velocity and measured volume. Able to flow a desired and pre-controlled volume independent of time, ranging from few ml/hour to litres per stroke. Each diaphragm SUP with diameter / volume, such as 100 mm / 0,5 litre, 150 mm / 1,7 litre, 220 mm / 5,5 litre is capable of 1:5.000 in dynamic range. In principle requiring only one 220 mm SUP covering the entire CFF range from 0,1 m2 to 10 m2 surface.

OPERATION METHODS

In general the 3 most used cultivation, fermentation and operation modes for a bioreactors or fermenters harbouring suspended micro-organisms as bio mass are;

-   batch with constant Working Volume (WV) and one time harvest with     typical 5 and if successful 10 mio cells/ml; -   fed-batch starting up with minimal WV and process media sequentially     or continuous being added for exponential increasing bio mass in     increasing Working Volume and one time harvest; -   perfusion with extraordinary high levels of typically suspended bio     mass, connected CFF devices for high levels of micro-organism     retention, sequentially Working Volume and sequentially or continues     media exchange and continues harvest.

Perfusion cultivation - additionally, the experienced user will preferably use the invented Disposable Bioprocess System platform as a PTF perfusion mode operating SUB in which a desirable average amount of micro-organisms, bio mass are kept in cultivation. The expressed product is removed sequentially though under continuous harvest for further down-stream processing. The micro-organisms within the SUB continue to grow exponentially and continue to express their desired product. As to this on a regular basis an amount of broth including the cells must be removed from the SUB and fresh media added. This sequentially part of the process loose biomass and product, but is the accepted method. As to this the micro-organism retention perfusion process is not a continuous process performing at steady state conditions. One or more CFF devises are typically used for separation of the desired expressed product from the media WV containing concentrated micro-organisms, nutrients, waste, product, etc. The retentate concentrate is returned to the SUB after retention in the CFF. The CFF is sequentially exposed to the liquid feed stock, process fluid from within the SUB, which sequentially separate the suspended micro-organisms / the retentate from the harvest / permeate now free from suspended micro-organisms. The CFF devise (one or more than one) may preferably be of single-use character and integrated within the SUB and all components assembled together and supplied sterilized in dual film bags. Conveyance of micro-organisms containing media from the SUB WV through and along the one or more channels in the CFF devise may be performed by one or more fluid conveying SUP devices. Pressure difference along and across the CFF will insure liquids from the SUB WV are sequentially conveyed to and occupying the entire interior compartment of the CFF channels for purification. The permeate side of the CFF may be either permanently or sequentially exposed for pressure lower than the (often atmospheric) pressure in the container. Removal of possible deposit / filter cake on the membrane surface is performed by rapid and or pulsating flow of liquid of such high velocity along the membrane surface that the particles adhering to the membrane is washed of, flushed back into the SUB container WV. Typical bio mass concentration for cultivation of mammalian cells with the cell retention systems here described range between 20 to 100 × 10E6 cells / millilitre or more.

The SUP is preferably also a disposable component and utilise a sensor able to give on-line information to a control device or a PCS, which can be used for velocity, volume and pressure control of said SUP. Preferable either a low cost SUS disposed with the invention or alternatively a high precision Re-Usable-Sensor. Good results have been obtained with a high precision tri-angular laser distance sensor able to measure between 30 and 200 mm length with resolution of 0,1 mm of the:

-   dynamic liquid level height in the SUP tubular cylinder with better     than 0,1 second response time; -   dynamic diaphragm position in the SUP body from beneath of the     elastic diaphragm.

The SUP in a first embodiment and size as presented in FIG. 1 supplied with a suitable drive pressure of 1 to 8 Bar is able to perform from 1 stroke per hour to one stroke per second reaching 20 m/s velocity in this CFF examples being a hollow fibre module with 12 fibre tubes each 0,5 to 1 mm inside diameter and 400 mm long. Volumes ranging from few ml/hour to 150 ml/sec per stroke for the air column driven SUP as show in the FIG. 1 setup with 34 mm inner diameter tube. Hollow fibre tube specifications may be altered according to SUB volume and CFF surface.

The SUP in a second embodiment and size as presented in FIGS. 6 and 7 represents a precision pump able to convey a programmable volume at a programmable velocity. Supplied with a suitable drive pressure of 1 to 8 Bar the SUP is able to perform from 1 stroke per hour to one stroke per second reaching 0,01 to 20 m/s or more velocity in a connected CFF device. Volume depending on the diaphragm diameter and expansion rate and range from ml to litres per stroke.

Knowing the real-time position of a piston surface, liquid surface, diaphragm surface then simple mathematical calculation performed by a computer give accurate info about motion, velocity, volume ousted, etc.

Motion of said piston surface, liquid surface, diaphragm surface activated by drive gas pressure ranging from absolute to over atmosphere pressure. Pressure control by a pressure regulating valve, preferably a proportional valve. Said valve controlled by said computer or PCS.

The above described embodiments of the invented Disposable Bioprocess System are preferably connected to a PCS controlling the process variables and integrating the process information such as described in the process recipe:

-   the PCS connected to multiple sensors integrated in said SUB and SUP     and CFF from which the PCS continuously collects data of process     variables; -   the Disposable Bioprocess System operational parameters are     constantly altered by said PCS in communication with various     actuators, devices integrated internally in said SUB, CFF and/or SUP     or external to said Disposable Bioprocess System for process     parameter control.

The PCS comprising controls for various In & Out channels such as:

-   various electronic analogue as well as digital input channels for     measuring, collecting data from a range of sensors; -   various pneumatic, gas, electronic analogue as well as digital     output to a variety of actuators.

DESCRIPTION TO THE FIGURES

FIG. 1 illustrates in an x-ray view the invented sterile Disposable Bioprocess System 11 as supplied to the end-user fully assembled (here shown without a film protection bag). The SUB 12 container 12 a include a sensor 13 a, a sensor 13 b and a biomass sensor 13 c, twin impellers 17 c, 17 d mounted on shaft 17 a, and one aeration tube 13 e mounted through top cover 12 b. The SUB 12 comprises a container 12 a with vertical side wall 12 c and inside the container a reservoir 12 d and horizontal bottom wall 12 e. The optional SUP suction tube 12 f is connected via a 90 degree angled elbow arranged inside reservoir 12 d and penetrating through the container 12 a vertical side wall 12 c via a port 12 g to a first one-way SUP 15 inlet valve 14 a before the SUP 15. The SUP 15 include an electronic liquid level / volume sensor 15 a inside the SUP 15 housing 15 b and a sterile filter 15 c in series with the external and not shown drive gas control device. The CFF device 16 is arrange in series with and after a SUP 15 second one-way outlet valve 14 d. CFF 16 receives the broth via SUP 15 second outlet valve. CFF 16 liquid retentate pass exit port 16 b and is guided back to the SUB 12 via hose 16 c and through SUB 12 vertical exterior side wall 12 c inlet 16 c and dumped in the SUB 12 broth reservoir 12 d. The CFF 16 permeate outlet 16 h and 16 g, convey the product harvested through tube 16 e and tune tube 16 f. From the container 12 a top cover 12 b four externally arranged hoses 18 a, 18 b, 18 c, 18 d allow end-user to connect to external pumps and various media containers (not shown). The SUB 12 comprises a shaft 17 a extending via a bearing 17 e through the top cover 12 b into the container 12 a, wherein said shaft 17 a is equipped with means extending radially from said shaft 17 a providing the agitation, such as one or more impellers 17 c, 17 d.

FIG. 2 illustrate with a cross sectional view of the lower part as a container 22 with a vertical container wall 22 a and a supporting bearing 27 b arranged in the container 22 bottom wall 22 e into which a rotating shaft 27 a is supported. Said shaft 27 a is mounted with two impellers 27 c, 27 d. A PG 13,5 size sensor 23 b tip is shown. A first valve body 24 a is arranged on the exterior side of the container 22 vertical wall 22 a between the top cover (not shown) and the bottom wall 22 e. The valve body 24 a is arranged between a first support foot 24 b at container 22 interior side of wall 22 a and a second support foot 24 c at exterior side of container wall 22 a. The assembly of inlet foot 24 b and the inlet one-way valve 24 and the outlet foot 24 c convey liquid media in one direction from reservoir 22 d to SUP 15. The SUP 15 inlet 22 f vertical arranged suction tube 22 f is fixed at its top in an elbow 22 g inside reservoir 22 d and fixed onto the container interior side wall 22 c in a suitable height from bottom wall 22 e. The suction tube 22 f extent freely hanging in a suitable distance 22 h over the container interior side of bottom wall 22 e.

FIG. 3 illustrate with a cross sectional view a lower part of SUB 32 comprising a cylindrical container 32 a. The vertical arranged suction tube 32 f is fixed at the upper end in an angled elbow body 32 g inside the container 32 a onto the interior side of said container wall 32 c. The suction tube 32 f correspond through port 32 d in the container wall 32 c with a first inlet valve 34 a arranged inside support food 34 b said support foot arranged on the exterior side of the container wall 32 c. Support foot 34 b further support the SUP vertical cylinder 35 on the upper exterior side.

FIG. 4 illustrate one embodiment of the present invention in a cross-sectional view of a PTF perfusion system with view of a SUB 41 with container wall 42 a and a supporting bearing 47 b at the bottom wall into which a rotation shaft 47 a is supported. The shaft 47 a is equipped with two impellers 47 c, 47 d and a Head-Plate-Drive bearing support 47 e mounted in cover wall 42 h facilitating an externally top mounted servo motor (not shown). A PG 13,5 based sensor 43 b and a similar size biomass sensor 43 c is shown extending into the broth reservoir 42 b through the top cover wall 42 h. A first inlet valve 44a body is shown arranged outside the container 42 a exterior side wall between the SUP 45 and the SUB 41 insuring one way direction liquid flow drawn from the media reservoir 42 b. The vertical arranged suction tube 42 f is fixed in a 90 degree angled liquid conveying body 42 g inside and onto the container 42 a side wall. The SUP cylinder 45 in arranged external to the SUB 42 after the first inlet valve 44 a and receive process broth passing the first inlet valve 44 a from the media reservoir 42 b inside SUB 41.

FIG. 5 illustrate one embodiment of the present invention with one or more Disposable Bioprocess System’s 51 installed in a block 59 a designed for thermal control and mechanical support. If desired also for agitation purposes of one or more (59 a, 59 b, 59 c, 59 d) individual Disposable Bioprocess System’s 51 being operated in parallel by a PCS (not shown). SUP 55 and CFF 56 shown installed on SUB 59 a including only the CFF 56 return connecting hose 56 a. All other hoses and accessories and sensors not show for simplicity.

FIG. 6 show an embodiment and the re-circulating liquid flow path in a PTF setup. A SUP 62 conveying broth between the SUB 60 and the CFF 64 and return the liquid to the SUB 60.

The SUB 60 container agitate continuously the liquid broth with an impeller 61 a mounted on a shaft 61 b driven by external means (not shown) said shaft attached to rotating magnetic device 61 c. A suction tube 62 b penetrate through the SUB 60 cover wall 60 a into the SUB 60 interior liquid broth reservoir 60 b. SUP 62 sucks liquid broth through a first valve 62 a via tube 62 d from SUB 60 liquid reservoir 60 a and convey via hose 62 c broth to said first valve 62 a located on the SUP 62 dome wall 62 d. Said first one-way valve 62 a receive broth from SUB 60 and pass the broth volume further on to the internal pumping chamber of the SUP 62 when SUP 62 are in suction, filling mode. A second one-way valve 62 e receive broth from SUP 62 outlet and opens and convey broth from SUP 62 internal pumping chamber when SUP 62 are in pumping mode. Port 62 g allow drive gas to enter SUP 60 for operation purposes. Said broth pass on to CFF 64 broth inlet port 64 a and said CFF 64 convey the broth along its internal porous membrane (not visible) inside the CFF 64 tubular container 64 b in which the CFF 64 convert broth to both retentate and permeate. Said retentate of CFF 64 exit port 64 c and is returned to SUB 60 via hose 64 d closing the process liquid loop. Said CFF 64 allow an amount of the liquid broth to pass the CFF porous membrane through one of or both of the permeate outlet ports 64 e, 64 f.

For simplicity only one sensor 60 c is shown entering the container reservoir 60 b through the cover wall 60 a, other necessary hoses and sensors are not shown, no sensors inside SUP 64 is shown.

FIG. 7 show in 7 a the SUP 72 assembled with CFF 74 connected and in 7 b show the individual parts before assembling.

The SUP 72 comprises the expanded, curved elastic diaphragm 72 a separating and suspended between the upper housing dome part 72 b and lower housing part 72 c. The dome 72 b is secured mechanically with a coupling (not shown) to the re-usable SUP lower housing part 72 c, which gives balance and support to the vertically arranged CFF 74. The SUP 72 facilitate a port 72 d (62 g) for the drive gas supply from external source (not show). The dome 72 b exterior wall is equipped with the first inlet valve 72 e housing and a second outlet valve 72 f connected directly to the CFF 74 broth inlet port 74 a. The curved single-use dome 72 b is on the interior side of the flat circumference wall 72 g attached fluid tight with a thin elastic curved diaphragm 72 a separating the sterile, wetted environment 72 h on the interior diaphragm side from the non-wetted non-sterile drive gas compartment 72 i exterior side of the diaphragm. The SUB 60 suction tube 62 b continuous into a hose 62 c which continues to the SUP 62/72 inlet valve 62 a/72 e via first inlet port 72 l. The first inlet valve 72 e allow one direction broth flow from the SUB 60 into the SUP 62/72. The SUP 72 second outlet valve 72 f allow broth in one direction to be conveyed from the SUP 72 pumping chamber 72 h via second outlet port 72 m to the CFF 74 first inlet port 74 a. The CFF 74 facilities the broth to pass along its internal porous membrane surface (not shown) to the CFF 74 second exit port 74 b from which a hose 64 d insure the now retentate is guided, conveyed back into the SUB 60 reservoir and mixed with the broth finishing the PTF liquid cycle. A CFF 74 third and fourth permeate outlet ports 74 c, 74 d convey filtered process liquid to said exterior facility area as harvested product.

SUP 72 re-usable lower housing part 72 c comprise a drive gas connection port 72 d for controlled SUP 72 activity and a housing flange 72 j suitable for gas tight connection with the diaphragm 72 a circumference seal 72 k.

Broth entering the SUP 72 pumping chamber 72 h is enclosed, trapped between the elastic freely floating diaphragm 72 a and the single-use rigid dome upper housing part 72 b.

FIG. 8 block diagram illustrate and describe a relevant and practical flow diagram for a continuous cultivation and harvest process with a first container SUB 80, a liquid conveying second container SUP 82 and a third container CFF 84 in a closed process liquid loop.

The first container 80 house the biological activity process and convey cultivation broth to the second container SUP 82. The SUP pump broth to third container CFF 84 for separation into harvest and process liquid in return loop back to the SUB 80.

The first container SUB 80 comprises a broth outlet port 80 a, a fresh media pump 80 b and inlet port 80 c, an agitation device 80 d driven by servo motor 80 e, a Glycose sensor 86 a, a Lactate sensor 86 b, dual biomass sensor 86 c, a pH sensor 86 d, a dissolved oxygen sensor 86 e, a 86 f temperature sensor and SUB temperature controlled via heating element 86 g. Fresh media is added via pump 80 b and used media (including cells), waste removed via pump 80 f. Aeration gas added to the SUB via control valve 80 g and sparged into the process broth 80h liquid volume and exhausted out through vent filter 80 i.

The second container SUP 82 houses the pumping process and comprises a broth volume 82 a and a drive gas volume 82 b. Drive gas inlet 82 c, a first inlet port 82 d associated with first inlet valve 82 e, a second outlet port 82 f associated with a second outlet valve 82 g, a liquid sensor 82 h, a pressure sensor 82 i, a drive gas port 82 j connected to external mounted dual proportional valves 82 k, 82 l (one valve for vacuum and one for pressure drive gas). The liquid sensor 82 h give in real-time information to the PCS (not shown) about the liquid level height, which the PCS use to adjust SUP 82 drive gas pressure (from absolute pressure to over atmospheric pressure) via external dual valve arrangement 82 k, 82 l.

The third container CFF 84 houses the separation process and comprises a separating porous membrane 84 a inside a CFF housing 84 b with a broth side 84 c and a permeate side 84 d. CFF container 84 comprises a broth inlet port 84 e and dual permeate outlet ports 84 f, 84 g and one retentate exit port 84 h. Between permeate outlet port 84 g and retentate exit port 84 h a TMP sensor 84 i is mounted. CFF 84 retentate exit port 84 h guide retentate in process liquid loop to the SUB 80 and optionally use a control valve 84 j in the retentate return line 84 k for various process adjustments. Said CFF device 84 facilitate on its permeate side 84 d one or more outlets 84 f, 84 g for product removal via optional controlled pumps (or optional valves) 84 n, 84 o.

In general the mechanically design is unlimited and illustrated without any PCS or control package or external liquid reservoirs associated with the Disposable Bioprocess System embodiment.

While the present invention has been described in connection with particular embodiments thereof, it will be understood by those skilled in the art that many changes and modifications may be made without departing from the scope of the invention as defined by the appending claims. 

1. A disposable and pre-sterilized bioprocess system for processing a biological material contained in a liquid, comprising: a) at least one first housing for conveying the biological material containing liquid, wherein the at least one first housing has at least one stationary wall surrounding at least one chamber comprising a pumping element for conveying the biological material containing liquid, wherein a Programmable Logic Control System (PLC) for regulation purposes receives information for either velocity, or revolution, or volume or pressure or time of said liquid passing the pumping element said pumping element regulation based on a program stored in a memory of the PLC, wherein the at least one first housing for conveying the biological material containing liquid is selected from the group consisting of: (i) a centrifugal pump, wherein the pumping element is a rotating element, and (ii) a peristaltic pump, wherein the pumping element is a tube situated between at least two moving elements and a stationary wall, b) at least one second housing comprising at least one permeable membrane filter having a non-filtered liquid and a filtered liquid side, the at least one second housing having at least one first housing port being a non-filtered liquid entrance and/or exit port, the at least one second housing having at least one second housing port being a non-filtered liquid exit and/or entrance port, the at least one second housing having at least one third housing port being a concentrated liquid permeate exit port, and wherein the at least one first housing port is in liquid communication with said non-filtered liquid side of said at least one second housing and said at least one second housing port conveys harvested and filtered liquid that has passed through said at least one permeable membrane filter of said at least one second housing.
 2. The disposable and pre-sterilized bioprocess system of claim 1, wherein said at least one first housing for conveying the biological material containing liquid is a peristaltic pump wherein the pumping element is a tube situated between at least two moving elements and a stationary wall, wherein any position of the at least two moving elements is controlled by the PLC.
 3. The disposable and pre-sterilized bioprocess system of claim 1, wherein said at least one first housing for conveying the biological material containing liquid is a centrifugal pump wherein the pumping element is a rotating element, wherein any position of the at least one rotating element is controlled by the PLC.
 4. The disposable and pre-sterilized bioprocess system of claim 1, wherein any position of the pumping element is measured in real-time.
 5. The disposable and pre-sterilized bioprocess system according to claim 1, wherein the liquid communication of the at least one first housing port with said non-filtered liquid side of said at least one second filter housing port is a plastic or silicone tube or pipe.
 6. The disposable and pre-sterilized bioprocess system according to claim 1, wherein any fluid communication to and from the at least one first housing port is measured by at least one flow sensor and/or at least one pressure sensor.
 7. The disposable and pre-sterilized bioprocess system according to claim 1, wherein any fluid communication to and from the at least one second housing port is measured by at least one flow sensor and/or at least one pressure sensor.
 8. The disposable and pre-sterilized bioprocess system according to claim 1, wherein said non-filtered liquid communication of the at least one first housing exit port with the at least one preferable two or more second housing inlet ports said second housing comprising a permeable membrane filter said non-filtered liquid communication is controlled by one or more valves.
 9. The disposable and pre-sterilized bioprocess system according to claim 1, wherein said filtered liquid communication of the at least one preferable two or more second housing exit ports is controlled by one or more valves. 